KELCO F60 Mk2 Installation & Programming Manual

Digital pump controller

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KELCO F60 Mk2

DIGITAL PUMP CONTROLLER

Installation & PROGRAMMING

MANUAL

Version 010319

KELCO

Engineering Pty Ltd

Sydney Australia

www.kelco.com.au

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Summary of Contents for KELCO F60 Mk2

Page 1 KELCO F60 Mk2 DIGITAL PUMP CONTROLLER INSTALLATION & PROGRAMMING MANUAL Version 010319 KELCO Engineering Pty Ltd Sydney Australia www.kelco.com.au...
Page 2 IMPORTANT: READ THIS FIRST DO NOT EXPOSE THE F60 Mk2 TO VIBRATION. INSTALL ONLY IN PIPEWORK THAT DOES NOT VIBRATE. Vibration will damage the electronics within the F60 and will void your product warranty. This F60 pump controller has been fully tested and calibrated. It is set to mode 1 and it has its start-up and run-on timers both set to 5 seconds.
Page 3 LCD SCREEN BACKLIGHT The LCD backlight can be turned on or off. To turn the light off press and hold down the (˅) button. Press and release the (R) button. Release the (˅) button. Repeat to turn the light on. The light remembers the state it was last left in if power is turned off.
Page 4 4) Never expose the F60 to static or dynamic pressures greater than 20 Bars, 290 psi. 5) Do not install the F60 in a section of pipe that is subject to vibration. Vibration will cause premature failure of the electronic components within the F60.
Page 5 LOCATION The F60 should be installed in a straight section of pipe preferably with 5 diameters of straight pipe either side of the paddle. The F60 can be installed in a suitable pipe socket, tapping saddle or pipe tee. The F60 should be installed in the discharge pipework of the pumping system, either before or after the system’s air cell.
Page 6 BEFORE THE AIR CELL If the F60 is installed before the air cell in the system it will only start the pump on pressure since the initial ﬂ ow will be supplied from the air cell. The only change in state the controller will see will be the falling pressure. Choose this arrangement if you want to keep pump starts to a minimum and you are prepared to accept the delay in starting associated with the slow pressure fall from the air cell.
Page 7 AFTER THE AIR CELL If you install the F60 in the pipework after the air cell it will start the pump each time ﬂ ow pushes its paddle forward or each time pressure falls to whatever pressure you have set the controller to start at. Choose this arrangement if you want the system to deliver a steady pressure and to start each time ﬂ...
Page 8 INSTALLATION The F60 pump controller is supplied as two separate assemblies, the paddle assembly and the electrical housing. The paddle assembly should be installed in the pipework ﬁ rst.
Page 10 It will then determine if the selected paddle dimensions are adequate for the application. Spare paddles to suit the F60 are available from Kelco or from your distributor. To ﬁ t the paddle assembly into the pipework, apply Teﬂ on tape or thread sealing compound to the thread and use a suitable spanner and the spanner ﬂ...
Page 11 order. There is a ﬂ at keying face on the cylindrical body of the paddle assembly that keys the electrical housing onto the paddle assembly and aligns it correctly. It is critical that the keying ﬂ at is on the downstream side and at 90 degrees to the axis of the pipework.
Page 12 anti-clockwise (outward) the force against the paddle that resists ﬂ ow will be reduced. The paddle will become increasingly more sensitive and will respond to progressively lower ﬂ ows the further out you wind the adjusting screw. The total adjustment range is 10 turns of the screw. If you wind the adjustment screw out beyond 10 turns there will not be enough residual force to return the paddle to the off position when ﬂ...
Page 13 TYPICAL DUAL PUMP SET A typical dual pump set is depicted in the accompanying sketch. The F60 and the F21 paddle ﬂ ow switch are installed in the discharge pipes from the pumps prior to their entry into the common discharge manifold. The remote ﬂ...
Page 14 WARNING All electrical work associated with the F60 must be carried out by qualiﬁ ed electrical personnel and all electrical work must conform to AS/NZ standards and to local wiring rules. ELECTRICAL INSTALLATION INTRODUCTION When used with its HD terminal link in place, the F60 can directly control single-phase pump motors to 2.4kW via Relay 1.
Page 15 WARNING The HD terminal must be left unused or only ever linked to Relay 1 Normally Open. It must never be used for any other purpose and it must never be connected to any external device. Under no circumstances connect the HD terminal to the terminals of Relay 2. The HD terminal must be regarded as live at all times and at full mains potential.
Page 16 BROWNOUT OR BLACKOUT If a blackout or brownout occurs the F60 will not retain any memory of where in its run or stop cycle it may have been, it will simply shut down the pump. When power resumes, the F60 will reboot, restart the pump and run any timer settings from the beginning.
Page 17 SUPPLY VOLTAGE LIMITS VOLTAGE LIMITS ON TERMINALS FELV & N Maximum Supply Voltage 25VAC 50/60Hz or 25VDC Minimum Supply Voltage 18VAC 50/60Hz or 18VDC VOLTAGE LIMITS ON TERMINALS A & N Maximum Supply Voltage 260VAC 50/60Hz Minimum Supply Voltage 110VAC 50/60Hz RELAYS The F60 houses 2 relays.
Page 18 POWERING THE F60 The power required to drive the F60 depends on the supply, AC or DC and on temperature. The table below gives the maximum power required from various supplies at 25°C. As temperature increases the power requirement will reduce. For example, at 30°C the power requirement will be approximately 3% less than the values given in the table.
Page 19 REMOTE INPUTS WARNING: The low voltage source available at the FELV terminal is non-isolated and must be regarded as operating at full mains potential whenever the F60 is powered from the mains. FELV means Functional Extra Low Voltage and refers to a non-isolated extra low voltage source.
Page 20 capacitive coupling between the adjacent wires. When set up this way cable resistance becomes the limiting factor for distance. The table below sets out the resistance of typical copper wire of various diameters. Note that the cable resistance refers to the total resistance out to the remote switch and back, as measured at the controller across the 2 remote connection wires with the external remote switch closed.
Page 21 WIRING DIAGRAMS PLUG AND LEAD WIRING Optional voltage free external input All electrical wiring associated with this controller must be carried our by a qualified electrician Earth Link CONNECTIONS FOR A SINGLE PHASE PUMP Supply 110 ~ 240VAC 50/60Hz. Active This link wire must be used whenever the controller is directly controlling a single phase pump motor, as shown.
Page 22 DUAL SINGLE PHASE PUMPS & 2 REMOTE INPUTS Supply 110 ~ 240VAC 50/60Hz. This link wire must be used whenever the controller is directly controlling a single Active phase pump motor, as shown. Do NOT use the HD link in 3 phase or single phase control circuit Neutral applications Remote switches with...
Page 23 BASIC 3 PHASE PUMP CONTROL Contactor WARNING Contactor coil rating must not exceed 240VAC 3 Phase Pump Motor DUAL 3 PHASE PUMP CONTROL Contactor 1 3 Phase Pump Motor 1 Contactor 2 WARNING 3 Phase Pump Motor 2 Contactor coil rating must not exceed 240VAC...
Page 24 2. The remote ﬂ ow switch can be a paddle style switch such as the Kelco F21 as depicted or an in line style ﬂ ow switch such as a Kelco C25-B. The remote ﬂ ow switch must have voltage free...
Page 25 3 PHASE CONTROL WITH ALARM & REMOTE INPUT Remote switch with NO or NC voltage free contacts Alarm 16A 240V Maximum resitive load Contactor WARNING Contactor coil rating must not exceed 240VAC Three Phase Pump Motor...
Page 26 THE 12VDC F60-12 PUMP CONTROLLER A low voltage DC version of the F60 is available for battery operation and for use in solar pumping systems. Functionally the F60-12 model is the same as the mains voltage model except for the terminal block markings. On the 12VDC model the active and neutral terminals are replaced by a positive + and negative –...
Page 27 PROGRAMMING THE F60 Mk2 For a description of the functions of the buttons and lights, please read pages 2 and 3 of this manual before proceeding. RESTORING FACTORY DEFAULTS (Purging the Settings) Provided the F60 is unlocked, you can restore its default factory settings at any time by pressing and holding down the (P) button and pressing and then releasing the (R) button.
Page 28 KELCO www.kelco.com.au This is the ﬁ rst screen in the menu Press and release (P) again. PUMP CONTROLLER MODEL F60 Mk2 Displays the model number Press and release (P) again. VERSION 000000. The version number must match the version number on the cover of this book.
Page 29 Mode 1 Timer Control In mode 1 the F60 operates on ﬂ ow only. Mode 1 provides you with a set of basic timers that includes a start-up timer to allow the pump to initially start regardless of lack of ﬂ ow and a run-on timer to ignore short term interruptions to ﬂ...
Page 30 Mode 5 Dual Pump Control Mode 5 conﬁ gures the F60 to control 2 independent pumps. The 2 pumps can be set to operate as a duty and standby set or as a dual alternating pump set. It can also be set up as a duty and line boosting or jockey pump set.
Page 31 USE REMOTE 1 FOR START & STOP Select this option if you are using a remote high and low level tank level switch. LOCAL FLOW OFF - USE REMOTE FLOW (In mode 5 only) This option disables the F60’s ﬂ ow sensing paddle. It allows a remotely mounted ﬂ ow switch to monitor ﬂ...
Page 32 CLOSED WHENEVER PUMP IS ON Relay 2 is closed while the pump is on, provided the F60 is powered. CLOSED DURING PRE-START DELAY Relay 2 can be used to run peripheral equipment such as a mixer prior to the pump starting. Relay 2 opens when the pre-start timer times out and turns off the peripheral equipment.
Page 33 time the F60 boots up and starts the pump. Its purpose is to allow time for the system pressure to rise to above whatever low pressure trip point you may have set. The pressure timer can be set to any time from zero to 900 seconds.
Page 34 This resets the burst pipe detector’s timer back to its original setting. If, however, the pump continues to run, due perhaps to a burst pipe, it will eventually reach the set point. The pump will then be instantly shut down preserving whatever source water remains, or at least reducing the discharge ﬂ...
Page 35 bore pump motors are particularly prone to damage from excessive cycling (starting and stopping). MAXIMUM STARTS PER HOUR The anti-cycling option built into the F60 allows the user to set the maximum number of times the pump can be safely started in any one hour period. If you select yes to using anti-cycling the screen that follows will ask you to enter the maximum number of times the pump can be started in any one hour.
Page 36 SET A LOW TRIP PRESSURE POINT Modes 2 3 5 The low trip pressure allows you to set a pressure trip point that can be used to shut a pump down if it is operating at an unusually low pressure. The low trip pressure is a pressure point that will sit below the normal cut in pressure.
Page 37 is factory set to 5 seconds. This can be adjusted between 0 and 900 seconds using the (˅) or (˄) button. If the dip timer is set to 0 the pump will be shut down the instant pressure falls to below the low trip pressure. HIGH PRESSURE TRIP Mode 4 Mode 4 asks you to enter a high-pressure trip point.
Page 38 WARNING: Never apply this function to a helical rotor pump or to any positive displacement pump. Helical rotor pumps and PD pumps in general may be damaged by the application of this function. Take great care in using the high pressure run-on and its associated settings.
Page 39 the high pressure run-on timer. As pressure rises ﬂ ow reduces and in some situations the ﬂ ow may have reduced to a point where the F60’s paddle can no longer detect ﬂ ow. In such situations the pump may be running, held on by the (ﬂ ow based) run- on timer.
Page 40 SET THE PRESSURE PUMP TWO Mode 5 In mode 5, set the starting and stopping pressure for pump 2. Pump 2 refers to the pump controlled by relay 2 in the F60. The start pressure for pump 2 must be set higher than the low-pressure trip point (if used) and must also be lower than the stop pressure for pump 2.
Page 41 HOW FLOW DETECTION WORKS Flow detection works with the run-on timer and shuts the pump(s) down at the end of the run-on time if ﬂ ow has failed to recover. If you alternate the pumps, if ﬂ ow is lost and pressure is above the starting pressure of the currently running pump, the pump will be shut down and the F60 will revert to a waiting state displaying WAITING TO...
Page 42 REPEATED RESTARTS ON A FAULT YES. Select this option if you want the pump to repeatedly try to restart after the delay period. LEAK DETECTOR Mode 3 The F60 includes a tool to analyse suspected leakage in a pressurised pumping system. To use the leak detector, open all valves feeding into the pipe system to be tested.
Page 43 This Warranty and Limitation of Liability (or any more recent version in effect when you purchase a Kelco Product) (“Warranty”) applies to all Kelco Products regardless of where you purchased the Kelco Products.
Page 44 Fitness of Kelco Products in a Customer Application. (3) You will conﬁ rm that Kelco Products are properly wired and installed for their intended use in your overall system. In the case of Kelco pump controllers, the ﬂ exibility of their operating system means it requires an extensive knowledge of pumps and their characteristics and the intended overall goal of the system in order to select the correct functions and settings.
Page 45 Products by the customer. . (2) Sole Remedy: Unless required to do otherwise as a result of statutory guarantees applicable under ACL, Kelco will provide, at its own discretion, either of the following two services as the sole remedy for a malfunctioning Kelco Product:...
Page 46 Failure due to customers over tightening threads or (4) If you intend to make a claim under this Warranty you must contact Kelco to register your claim by telephone on (02)99056425 and provide the following details to enable Kelco to assess the claim: (i) proof of purchase;...
Page 47 Australia. At its discretion Kelco may not provide customers with Kelco Products and/or technical documents should they fail PLEASE NOTE: Kelco Engineering Pty Ltd reserves the right to change the speciﬁcation of this product without notice.

KELCO F60 Mk2 Installation & Programming Manual

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